Web forming machine

ABSTRACT

A web forming machine, and a method of forming a web is described and which includes a first rotatable assembly; a second rotatable assembly positioned in spaced relation relative to the first rotatable assembly, and wherein a gap is defined between the first rotatable assembly, and the second rotatable assembly; and wherein a web of material to be formed is received in the gap; and means for reciprocally moving the first rotatable assembly into contact with the web, and into mating relation relative to the second rotatable assembly.

RELATED PATENT DATA

This application is a continuation of Jensen, U.S. patent applicationSer. No. 11/244,722, filed Oct. 6, 2005, which is a continuation of U.S.patent application Ser. No. 10/798,103, filed Mar. 10, 2004, bothentitled “Web Forming Machine”, and both of which are incorporatedherein by reference in their entireties, including drawings.

TECHNICAL FIELD

The present invention relates to a web forming machine, and morespecifically to an apparatus having cooperating first and secondrotatable assemblies, and wherein one of the rotatable assemblies isreciprocally movable relative to the other. The invention findsusefulness for rapid, continuous, punching, forming or shearing of weblike material such as sheet metal, and the like.

BACKGROUND OF THE INVENTION

The prior art is replete with numerous examples of sheet metal cuttingand forming devices which have been fabricated for various purposesincluding specific operations such as cutting, perforating, embossing,crimping, and forming to name but a few. As a general matter,conventional sheet metal cutting and forming devices are typicallyfabricated utilizing numerous reciprocating presses. In this regard,material to be worked is placed within a press; positioned in astationary location over a die; and thereafter the press, which isusually mechanically operated, is closed thereby forcing a second dieinto contact with the material being worked. Upon completion of theperforation or other forming step, the press is opened and the materialbeing worked or other work piece is removed and a new work piece islater inserted; or the material being worked is indexed to a newposition such that the process can be repeated.

Various solutions have been suggested for increasing the speed ofoperation of such devices. For example, in U.S. Pat. No. 4,732,028 theteachings of which are incorporated herein, one prior art solutionincluded the use of a so-called flying shear or die which is used with astrip which is moving continuously. In this system, the die isaccelerated to the speed of the strip, and the press closes while thedie and strip are moving in unison. The die then opens and returns toits starting position. Typically the punching, forming and shearing ofcontinuous material utilizing a device such as this is limited to a linespeed of about 250 feet per minute.

The prior art further discloses various rotary machines which are usefulin shearing or forming web-like material. However, in the use of suchdevices it is well known that flat dies used in conventionalreciprocating presses do not operate in such devices. Still further,considerable problems are encountered in the use of curved dies. In thisregard, many prior art references teach and acknowledge that curveddies, while they will work on various materials, will often causedeformation and distortion of a work piece.

In addition to the foregoing difficulties, many products that arefabricated from web-like material such as sheet metal, and the like,often require that different sized apertures be formed in variouslocations in the web in order to form a resulting work piece. Examplesof such work pieces such as metal structural members, are illustrated inFIGS. 1A, 1B and 1C, respectively. As will be appreciated from studyingthose Figures, the positioning of appropriate dies in the correctlocations and the proper distances presents difficulties in themanufacturing process. Typically, the machines which are useful for thispurpose are very long in length, and the resulting control systemsnecessary to control the speed as well as the positioning of the webmaterial relative to the various rotary presses needed for such endproducts presents assorted difficulties.

Therefore, a new and improved web forming machine which addresses theseand other shortcomings attendant with the prior art practices andapparatuses utilized heretofore is the subject matter of the presentinvention.

SUMMARY OF THE INVENTION

One aspect of the present invention relates to a web forming machinewhich includes a first rotatable assembly; a second rotatable assemblypositioned in spaced relation relative to the first rotatable assembly,and wherein a gap is defined between the first rotatable assembly, andthe second rotatable assembly, and wherein a web of material to beformed is received in the gap; and means for reciprocally moving thefirst rotatable assembly into contact with the web, and into matingrelation relative to the second rotatable assembly.

Still another aspect of the present invention relates to a web formingmachine and which includes a work station; a selectively rotatable andmoveable punch assembly positioned above, and in spaced relationrelative to, the work station; a selectively rotatable die assemblypositioned below the work station and which is operable to matinglycooperate with the punch assembly; a web of material selectivelypositioned in the work station, and wherein the punch assembly ismoveable along a path of travel and into penetrating contact with theweb and into mating relation relative to the rotatable die assembly; acomputer memory which stores at least one pattern of apertures which areto be formed in the web; and a controller electrically coupled with thecomputer memory, and further controllably coupled with each of therotatable punch and die assemblies, and further controllably positioningthe web in the work station, and wherein the controller selectivelycauses the rotational movement of the rotatable punch and die assembliesand the selective positioning of the web, and further causes therotatable punch assembly to move along the path of travel and intopenetrating contact with the web to form the at least one pattern ofapertures which are stored in the memory.

A further aspect of the present invention relates to a method of forminga web which includes providing a web of material having a top and bottomsurface; defining a work station and selectively positioning the web ofmaterial in the work station; providing a selectively moveable androtatable punch assembly and positioning the moveable and rotatablepunch assembly in spaced relation relative to the top surface of theweb; providing a selectively rotatable die assembly and positioning theselectively rotatable die assembly in an adjacent position relative tothe bottom surface of the web; and forming at least one aperture in theweb of material by moving the rotatable punch assembly into penetratingcontact with the top surface of the web and into mating engagement withthe rotatable die assembly.

These and other aspects of the present invention will be discussed ingreater detail hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below withreference to the following accompanying drawings.

FIGS. 1A, 1B, and 1C, are plan views of portions of web material havingvarious apertures or other elevated structures formed thereon.

FIG. 2A is a side elevation view of a portion of a web forming machinein accordance with the teachings of the present invention.

FIG. 2B is a side elevation view of yet another portion of the webforming machine and which is positioned downstream from that portion ofthe web forming machine shown in FIG. 2A.

FIG. 2B1 is a fragmentary, transverse, enlarged vertical sectional viewtaken through a portion of the structure shown in FIG. 2B as indicatedby the arrow in the drawing.

FIG. 2B2 is a fragmentary, transverse, enlarged vertical sectional viewof a portion of the web forming machine as shown in FIG. 2B.

FIG. 2C is a fragmentary, side elevation view of a portion of the webforming machine of the present invention, and which is positioneddownstream of that portion of the same machine as shown in FIG. 2B.

FIG. 3 is a fragmentary, transverse, vertical sectional view of aportion of the web forming machine as shown in FIG. 2.

FIG. 4 is a fragmentary, transverse, vertical sectional view of aportion of the web forming machine and which is taken from a positionalong line 4-4 in FIG. 3.

FIG. 5 is a fragmentary, transverse, vertical sectional view takenthrough the first and second rotatable assemblies of the presentinvention.

FIG. 6 is a fragmentary, transverse, vertical sectional view takenthrough the first and second rotatable assemblies of the presentinvention and which are shown in a second position.

FIG. 7 is a greatly simplified schematic diagram showing features of thecontrol system utilized with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of theconstitutional purposes of the U.S. Patent Laws “to promote the progressof science and useful arts” (Article 1, Section 8).

The web forming machine or apparatus of the present invention isgenerally indicated by the numeral 10 in FIG. 2, and following.Referring now more specifically to FIG. 2A, 2B, 2B1, 2B2 and 2C, a webforming machine of the present invention 10 is shown, and which ispositioned or otherwise mounted on a factory floor which is generallyindicated by the numeral 11. As seen in FIG. 2A, a pit 12 is formed inthe factory floor thereby defining a region through which a continuousweb of material, which will be described below, passes through, as it isbeing treated by the web forming machine 10. The web forming machine orapparatus of the present invention includes a first portion generallyindicated by the numeral 13 and which is shown in FIG. 2A, a secondportion 14 as best seen by reference to FIG. 2B, and a third portion 15as best seen by reference to FIG. 2C.

Referring now to FIG. 2A which shows the first portion 13 of theapparatus, it will be seen that the web forming machine 10 of thepresent invention includes a source of continuous web material hereillustrated in phantom lines as a coil of web material which isgenerally indicated by the numeral 20. The coil of web material 20 ismounted for rotational movement on a supporting frame which is generallyindicated by the numeral 21. The supporting frame 21 is affixed onto thefloor or other supporting surface 11. The supporting frame 21 has anapex 22 which supports the continuous coil of web material 20 in spacedrelationship relative to the floor 11. A motor 23 is affixed on the apex22, and is operable to selectively rotate the continuous coil of webmaterial 20. An advancing sheet of the continuous coil of web material24 is shown, and is received within, and acted upon by a device which isgenerally indicated by the numeral 30, and which is utilized toselectively advance the sheet of web material, and simultaneouslyflatten the advancing sheet so that it may be processed by otherassemblies of the web forming machine 10. This coil advancing device foradvancing the web of material 24 is known in the art, and is positioneddownstream relative to the source of the continuous web material 20. Thecoil advancing device 30 is operable to supply the advancing sheet 24 toa feed table which is generally indicated by the numeral 31. The feedtable has a base 32 which is fixed on the floor or other supportingsurface 11, and further has a moveable tabletop which is generallyindicated by the numeral 33. As seen in FIG. 2A, the tabletop ismoveable from a position 33A as seen in solid lines in FIG. 2A, where itsupports the advancing web of material 24; to a second position 33B,shown in phantom lines, whereby the fluid powered cylinders 34 move thetabletop 33 to a non-supporting position such that a loop of webmaterial 35 is received in the pit 12. This loop of web material 35allows the web forming machine 10 to have a ready supply of web material20 for the web forming process which will be discussed in greater detailhereinafter.

The web forming machine of the present invention 10 is operable to formvarious work products as seen in FIGS. 1A, 1B and 1C, for example. Forpurposes of the present application, the source of the continuous webmaterial 20 will hereinafter be referred to as a coil of sheet metal.This sheet metal is useful in forming, for example, metal structuralmembers as might be useful in building construction. However, it will berecognized that the coil of continuous web material 20 could containother materials such as paper, various synthetic plastics, cloth andother natural and manmade materials. The work products which aregenerally indicated by the numeral 40 in FIGS. 1A, 1B and 1C include afirst pattern of apertures and raised or elevated areas generallyindicated by the numeral 41; a second pattern as indicated by thenumeral 42; and a third pattern as indicated by the numeral 43. Each ofthe work products 40 which are formed of portions of the advancing web24, have a first end 44, and an opposite second end 45. Still further,each portion has a top surface 50 and a bottom surface 51. As seen inFIG. 1A, the first pattern of apertures or raised or elevated areas 41include a plurality of round apertures 52 which are positioned near theopposite ends and other locations which are at a predetermined spaceddistance from one of the peripheral edges. As should be appreciated,these work products 40, as illustrated in FIGS. 1A, 1B and 1C, may befurther bent or otherwise folded in various ways to form variousutilitarian shapes. It will be recognized therefore that the apertures,for example, may, following this bending or other deforming, actually bepositioned on resulting flange-like assemblies such as might be the casewhere the individual work products 40 are folded in order to formC-shaped or Z-shaped structure members or studs as might be useful inconstruction. As seen in FIG. 1B, a second pattern of apertures 42, andraised or elevated areas are shown. In this particular view, it will beseen that the second pattern may include round apertures 52 as well asoval or channel-shaped apertures 53. Still further, elevated or raisedareas 54 may be formed in the surface of the work product 40 for variouspurposes. Referring now to FIG. 1C, a third possible work product formedby the present web forming machine 10 may include both round apertures52, oval or channel shaped apertures 53 as well as other raised orelevated areas 54, all of which are disposed in given patterns along thetop surface of the work product 40. As should be understood, theapertures, or channels referenced above, extend between the top andbottom surface 50 and 51 thereof in order to provide a continuouspassageway.

Referring now to FIG. 2B which shows the second portion 14 of the webforming machine 10, it will be seen that the second portion 14 includesa plurality of work stations generally indicated by the numeral 70.These work stations are further identified as a first work station 71; asecond work station 72; and a third work station 73. As should beappreciated, the first work station 71 is positioned downstream relativeto the feed table 31 as seen in FIG. 2A. It will be further recognizedthat the loop of web material 35 in the pit 12 is further fedcontinuously into the first work station 71 as will be described infurther detail below. The second portion 14 of the web forming machine10 includes a base frame generally indicated by the numeral 74, andwhich is mounted in a fixed location on the floor or other supportingsurface 11. The base frame 74 has a top surface 75, and opposite firstand second ends 76 and 77, respectively. As seen in FIG. 2B aservo-pinch/roller assembly 80 of conventional design is mounted on thetop surface 75, and is positioned near the first end 76 of the baseframe 74. The servo-pinch/roller 80 includes a frame 81 which is mountedon the top surface 75. The frame 81 includes a first roller 82 which ispositioned in a fixed location relative to the frame 81 and which iscoupled in force receiving relation relative to a motor 83. The motor 83imparts rotational movement to the first roller 82. Further, a secondroller 84 is moveably borne by the frame 81. The second roller 84 isreciprocally moveable relative to the first roller 82 by means of afluid powered cylinder 85 which is mounted on the frame 81. A gap 86 isdefined between the first and second rollers 82 and 84, and thecontinuous web of material 24 is received therebetween. In operation,the first and second rollers 82 and 84 are moved into forcibleengagement one with the other thereby pinching the web of material 24therebetween. Rotational movement of the first roller 82 by means ofenergizing the motor 83 causes the web of material 24 to be selectivelyadvanced through the second and third work stations 72 and 73 as will bediscussed in greater detail hereinafter.

As seen in the longitudinal, substantially vertical sectional view ofFIG. 2B, which is taken through the second portion 14 of the web formingmachine 10, a pair of guide rollers 90 are provided, and which areoperable to receive and orient, or otherwise guide, the continuous webof material 24 through the first, second and third work stations 71, 72and 73. As should be appreciated, while one pair of guide rollers 90 areshown in FIG. 2B, there would be an opposite pair of guide rollers (notshown) positioned on the opposite side of the machine 10. The individualguide rollers are operable to engage the peripheral edge of thecontinuous web of material 24 thereby orienting and guiding itsubstantially along the top surface 75 of the base frame 74. The secondwork station 72, further includes a selectively moveable platen which isgenerally indicated by the numeral 91. The moveable platen has a topsurface 92, and further has formed therein a plurality of channels orpassageways 93 which extend through the moveable platen. As should beunderstood, a plurality of dies 94 are individually mounted on the topsurface 92 and are substantially coaxially aligned relative to therespective channels or passageways 93. The individual dies 94, each havea passageway 95 formed therein. A platen movement assembly 96 is shown,in phantom lines, and which is coupled in force transmitting relationrelative to the moveable platen 91. The platen movement assembly 95 isoperable to selectively position the moveable platen in variouslocations so as to appropriately position the respective dies so thatthey are substantially coaxially aligned with a punch assembly whichwill be discussed below. The platen is moveable in X and Y directions ina plane which is substantial parallel to the top surface 75. The controland operation of the platen movement assembly will be discussed ingreater detail with respect to FIG. 7 in the paragraphs below.

The second work station 72 further includes a frame 100 which is mountedon the top surface 75 of the base frame 74. The frame 100 mounts a fluidpowered ram assembly 101 on the top surface thereof. The fluid poweredram assembly includes a ram portion 102 which is reciprocally moveablealong a path of travel for the purposes which will be described below.The second work station 72 further includes a rotatable punch assemblywhich is generally indicated by the numeral 103. The rotatable punchassembly is selectively rotated by means of an indexing motor 104 (asseen in FIG. 7) into given orientations in order to position individualpunches 105 which are positioned thereabout the rotatable punch assembly103 into appropriate positions so that they may be individually movedsubstantially along a linear path of travel 110 and into deforming orpenetrating contact relative to the substantially continuous web 24, andinto mating engagement with the underlying substantially coaxiallyaligned dies 94 which are mounted on the top surface 92 of the moveableplaten 91. As should be understood, the ram portion 102 is disposed inforce transmitting engagement relative to the rotatable punch assembly103. Therefore, the first rotatable punch assembly is not only rotatableas indicated by the arrows, but is further selectively, reciprocallymoveable along a path of travel 110 from a first position 111, where theindividual punches 105 engage the continuous web 24 to deform orotherwise form apertures 52 and 53 as seen in FIGS. 1A, 1B and 1C,respectively, and then further is moveable by the same ram portion 102into a disengaged position 112, thereby permitting the continuous web ofmaterial 24 to be moved onto the third work station 73. As will beappreciated, while four punches 105 are shown in FIG. 2B it will beappreciated that, depending upon the diametral dimensions of therotatable punch assembly, more than four punches 105 may be mountedthereabout the first rotatable punch assembly. Still further, theplurality of punches 105 may be of different sizes and shapes in orderto form the round apertures 52, ovals or channel shaped apertures 53, orthe raised or elevated areas 54 in the work products 40 which are formedby the web forming machine 10.

Referring still to FIG. 2B, 3 and 4, the web forming machine 10 of thepresent invention includes a third work station 73, which is positioneddownstream from the second work station 72. In this regard, the thirdwork station 73 includes a frame which is generally indicated by thenumeral 120. The frame includes a pair of spaced apart frame members 121which are best seen in FIG. 3. The frame members have a first, or topsurface 122, and a second or bottom surface 123, which is affixed on thesupporting surface or floor 11. As best seen in FIGS. 3 and 4, a fluidpowered ram assembly 125 is mounted on the first or top surface 122, andincludes a reciprocally moveable ram portion 126 as seen in phantomlines in FIG. 3. The ram portion 126 has a distal end 130. Each of therespective frame members 121 defines a longitudinally extending channel131. As seen in FIG. 3, a first bearing block 132 is slideably receivedwithin one of the channels 131 of one of the frame members 121, and asecond bearing block 133 is received in the other of the two framemembers 121. As illustrated in FIG. 3, the distal end 130 of the ramportion 126 is affixed to these respective bearing blocks, and isoperable to reciprocally move the respective bearing blocks within eachof the channels 131. Referring still to FIG. 3, a motor 134 having amotor shaft 135 is mounted on the first bearing block 132. The motor,when selectively energized, is operable to impart rotational movement tothe motor shaft for the purposes which will be described in theparagraphs which follow. As will be appreciated, the respective fluidpowered rams 126 are operable to move the respective bearing blocksalong a substantially vertically disposed path of travel.

A first selectively rotatable and reciprocally moveable punch assembly140 is mounted in the third work station 73, and on the respective pairof frame members 121, as discussed above. The first rotatable punchassembly 140 has a cylindrically shaped main body 141 which has a firstend 142, and an opposite second end 143. As should be understood, themain body may assume other shapes. As seen in FIGS. 3, 5 and 6, forexample, the first rotatable punch assembly includes an axle which iscomposed of a first axle portion 144, which extends substantiallyaxially, normally, outwardly relative to the first end 142, and a secondportion 145 which extends substantially axially, normally, outwardlyrelative to the second end 143. The first and second axle portions aresubstantially coaxially aligned and define an axis of rotation 146 forthe moveable punch assembly 140. Still further, a fluid passageway 147is formed in the first axle portion 144, and is operable to deliver afluid under pressure, for the purposes which will be described ingreater detail hereinafter. As seen in FIGS. 5 and 6, for example, thefirst rotatable punch assembly has an exterior facing surface 150 whichhas a plurality of apertures or receiving stations 151 formed therein.Still further, a channel 152 is formed in the main body 141 andcommunicates with the exterior surface 150 as illustrated in FIGS. 3, 5and 6. The first rotatable punch assembly mounts a plurality ofdifferently sized and shaped punches 153 for forming the differentapertures 52 and 53 in the continuous web material 24. These differentapertures, of various shapes, and raised areas 54 are seen most clearlyin FIGS. 1A, B and C, respectively. Still further, at least onedeforming tool 154 is mounted on the exterior surface 150 and isoperable to form the various raised or elevated surface areas such asseen at numeral 54 in FIG. 1B. Additionally, a first portion of asevering tool 155 is borne by the first rotatable punch assembly and isoperable under certain conditions to shear or sever the web of material25 as will be discussed hereinafter and as more clearly seen in FIG. 4.

Referring now to FIG. 5, it will be seen that the first rotatable punchassembly 140 includes a punch orientation assembly which is generallyindicated by the numeral 160. The punch orientation assembly 160, whichis borne by the rotatable punch assembly 140, is operable in a firstmode of operation, as will be described below, to position at least onepunch 153 in a first position; and in a second mode of operation,permits the at least one punch 153 to move from a first radiallyextended position to a recessed, second position. More specifically, thepunch orientation assembly 160 as seen in FIG. 5 is operable to positionat least one punch 153 having a first end 161, and a second end 162, ina given, substantially radially extending orientation relative to theexterior surface 150 of the main body 141. In this regard, the punchorientation assembly includes a punch orientation frame 163 whichslideably positions the individual punches 153 in the first position oraxially extending orientation relative to the exterior surface 150. Asseen in FIG. 5, the punch orientation frame includes individualpassageways 164 which slideably or telescopingly receive the respectivepunches 153. Still further, the punch orientation assembly includes aslideably positionable orientation bar 170 within the channel 152 andwhich mechanically cooperates with the punch orientation frame. Theorientation bar 170 has a first end 171, and an opposite second end 172.Still further, individual passageways 173 are formed therein. Theorientation bar 170 is operable to move along a course of travel 174,between a first position 175, which defines a first mode of operationfor the punch orientation assembly 160; and a second position 176 whichdefines a second mode of operation.

As illustrated in FIG. 5, the first rotatable punch assembly 140 mountson the first end 142, a fluid powered actuator which is generallyindicated by the numeral 180. The fluid powered actuator has a moveableram 181 having a distal end 182 which is mounted in force transmittingrelation relative to the first end 171 of the orientation bar 170. Stillfurther, the fluid powered actuator 180 includes a fluid coupler 183which is connected in fluid flowing relation relative to the fluidpassageway 147 and which extends through the first axle portion 144. Asshould be understood, the selective supplying of fluid under pressure tothe fluid powered actuator 180 causes the moveable ram 181 to move theorientation bar 170 along the course of travel 174 between the first andsecond positions 175 and 176. While this fluid powered actuator isdepicted in FIG. 5 and FIG. 7 as hydraulically activated, it will berecognized that this same assembly may comprise a pneumaticallyactivated cylinder. As discussed above, in the first position 175, whichdefines the first mode of operation, and as seen in FIG. 5, theorientation bar is positioned such that the individual punches 153extend substantially radially, normally, outwardly relative to theexterior surface 150. In this position, the individual punches 153 areoriented such that when they are moved into contact with the continuousweb 24, they penetrate same in order to form the various apertures 52and other features in the web 24. Still further, and in the secondposition 176, which defines the second mode of operation, theorientation bar is positioned so as to orient the individual passageways173 in substantially coaxial alignment relative to the passageways 164which are formed in the punch orientation frame 163. When theserespective passageways are substantially coaxially aligned, theindividual punches 153 are able to move along the passageway 164 suchthat the first end 161 of the punches 153 are positioned in asubstantially co-planer relationship relative to the exterior surface150. When the first rotatable punch assembly 140 is moved into contactwith the continuous web 24 as will be discussed below, these individualpunches 153, do not penetrate the web 24. This, of course prevents anaperture 52 or 53 from being formed therein. It will be appreciated,therefore, that this arrangement provides a convenient means whereby anoperator can selectively form various aperture patterns and arrangementsdepending upon the design of the final end product.

A punch movement assembly is generally indicated by the numeral 190 inFIG. 6. The punch movement assembly is moveably borne by the rotatablepunch assembly 140, and is operable to move at least one punch 153 alonga course of travel which is substantially parallel to the axis ofrotation 146 of the rotatable punch assembly to change the relativeposition of the punch with respect to the exterior facing surface 150.In this regard, the punch movement assembly 190 is operable to move atleast one punch 153 which has a first end 191, and a second end 192,along a course of travel which will be described below. The punchmovement assembly includes a moveable punch frame 193 which is receivedin the channel 152 which is defined by the main body 141. The moveablepunch frame has a main body 194 which has a first end 195, and anopposite second end 196. Still further, at least one channel,passageway, or bore 200 may be formed in the main body 194, and isoperable to matingly receive the second end 192 of a punch 153. As seenin FIG. 6, the moveable frame 193 can be selectively positioned along acourse of travel 201 which is substantially parallel to the axis ofrotation 146. The course of travel 201 is defined between a firstposition 202 and a second position 203. A fluid powered actuator 204 isborne by the first end 142 of the first rotatable punch assembly 140.The fluid powered actuator includes a moveable ram 205 which is mountedin force transmitting relation relative to the first end 195 of themoveable punch frame 193. Still further, a fluid coupler 206 is coupledin fluid flowing relation relative to the fluid powered actuator 204.The fluid coupler 206 is coupled in fluid flowing relation relative tothe fluid passageway 147. As should be understood, the selectiveapplication of fluid pressure to the fluid passageway 147 has the effectof moving the ram 205, and thus the moveable punch frame 193 along thecourse of travel 201 to change the relative position of the respectivepunches 153 to the exterior facing surface 150.

Referring now to FIGS. 3, 5 and 6, the third work station 73 includes aselectively rotatable die movement assembly which is generally indicatedby the numeral 210. The selectively rotatable die movement assembly 210has a cylindrically shaped main body 211 which has opposite first andsecond ends 212 and 213, respectively. The main body 211 may also assumeother shapes. As seen in FIGS. 3 and 5, for example, a gap 214 isdefined between the selectively rotatable die movement assembly 210 andthe first rotatable punch assembly 140. As will be appreciated from astudy of FIG. 2B the substantially continuous web 24 is received in thegap 214 and thereafter is formed into a work product 40 as seen in FIGS.1A, 1B and 1C by the action of the rotatable punch assembly 140 actingupon the selectively rotatable die assembly 210. The selectivelyrotatable die assembly 210 rotates about an axle 215 which defines anaxis of rotation which is generally indicated by the line labeled 220.This axis of rotation is generally parallel to the axis of rotation 146of the rotatable punch assembly (see FIG. 6). These respective axes ofrotation are not coaxially aligned but rather are in spaced relation onerelative to the other. The axle 215 has a first axle portion 221 whichextends substantially axially, normally, outwardly relative to the firstend 212, and a second axle portion 222 which correspondingly extendssubstantially axially, normally, outwardly relative to the second end213. Still further, the main body 211 is defined by an exterior facingsurface 223 that has formed therein a channel which is generallyindicated by the numeral 224. Still further, various apertures 225 areformed in the exterior facing surface. Moreover, a fluid passageway 226is formed in the first axel portion 221.

As seen in FIGS. 5 and 6, a moveable die block 230 is received in thechannel 224. The moveable die block has a first end 231, and an oppositesecond end 232. Still further, at least one channel or bore 233 isformed in the moveable die block and is operable to matingly receive adie which is generally indicated by the numeral 234. The dies 234 are ofconventional design and have a passageway 234A extending therethrough.As seen in FIG. 5, a fluid powered actuator of conventional design 235is mounted on the first end 212 of the main body 211. The fluid poweredactuator includes a moveable ram 236 which is mounted in forcetransmitting relation relative to the first end 231 of the moveable dieblock 230. The selective application of fluid pressure to the fluidpowered actuator 235 causes the die block 230 to move along a course oftravel 240, which is generally parallel to the exterior facing surface223 of the main body 211. The fluid powered actuator 235 furtherincludes a fluid coupler 241 which is coupled in fluid flowing relationrelative to the fluid passageway 226 which is formed in the first axleportion 221. Those skilled in the art will recognize that this fluidpowered actuator may also comprise a pneumatically actuated cylinder.

As will be appreciated from a study of FIG. 6, the die block 230 isoperable to be positioned in a location such that the individual dies234 are substantially coaxially aligned relative to the punches 153which are mounted on the first rotatable punch assembly 140. As earlierdiscussed with respect to the punch movement assembly 190, the moveabledie block 230, as seen in FIG. 6 permits an operator, by means of acontrol system, which will be described hereinafter, to convenientlyposition both the punches 153, and the corresponding mating dies 234 invarious locations relative to the exterior facing surfaces of therespective assemblies 140 and 210 so that apertures 52 and 53 may bevariously located in the continuous web 24 which passes through the gap214. As best seen by reference to FIG. 3, a selectively actuatable motor243 is mounted on one of the frame members 121 of frame 120, and issubstantially coaxially aligned relative to the second bearing block133. The motor 243 may be selectively energized to cause the secondrotatable die assembly to index to an appropriate position so that itmay be substantially coaxially aligned relative to the mating punches153 which are mounted on the rotatable punch assembly 140. As seen mostclearly by references to FIGS. 4, 5 and 6, the first rotatable punchassembly is reciprocally moveable along a substantially verticallydisposed and linear path of travel 244 between a spaced first position245 which allows the passage of the web 24 through the gap 214 to asecond position 246 where the first rotatable punch assembly is movedinto forceable mating engagement with the selectively rotatable yet nowstationary die assembly to, on the one hand form apertures 52 and 53 inthe continuous web 24, or to otherwise deform the web, or to sever thecontinuous web as illustrated in FIG. 4 by the use of the severing tool155. The second portion of the severing tool is seen at numeral 246 inFIG. 4 and extends substantially radially outwardly relative to theexterior surface 223. The portion of the web 24 which is punched out toform the aperture 52 passes through the respective dies 225 and into aninternal passageway 247 where it then exits endwardly from the assembly210.

Referring now to FIG. 2C it should be understood that a sheet/webconveyor 250 is positioned downstream of the third work station 73 asdescribed above. As should be appreciated, once the substantiallycontinuous web 24 has passed through the third work station 73 thesheet/web conveyor 250 is operable to move the continuous web to afourth work station which will be described below. The sheet/webconveyor 250 is of conventional design having supporting legs 251 whichare mounted in a fixed position on the floor or other supporting surface11. The supporting legs position a conveyor bed 252 in spaced relationrelative to the floor. A motor 253 is mounted on the conveyor bed and isoperable to propel the conveyor bed, and the continuous web restingthereon in the direction of arrows as seen in FIG. 2C to the fourth workstation 260. The fourth work station 260 includes a supporting frame261, having a top surface 262, and a bottom surface 263 which rests in afixed location on the supporting surface 11. Still further, positionedalong the top surface 262 is a plurality of spaced, roll formers 264 ofconvention design. As many as 14 or more roll formers may be positionedin spaced locations along the top surface, only 2 are shown in thedrawings, and the others are indicated by the dotted lines in that view.These roll formers are operable to further act upon the continuous webof material 24 to bend or otherwise shape the continuous web into aresulting work piece 40 that may have a substantially C, Z or othershape. The web forming machine 10 has a discharge end generallyindicated by the numeral 265 where the resulting work product isremoved.

Referring now to FIG. 7, a simplified schematic depiction of a portionof a control system 280 which is useful in the practice of the presentinvention is shown. This schematic view shows the control system as itoperably couples with various assemblies made integral with theinvention 10 such as motors and various fluid powered actuators, and notthe entire assembly 10 in order to assist in an understanding of theinvention. In this regard, the control system 280 includes a computerwhich is generally indicated by the numeral 281 and which has a memorywhich stores at least one pattern of apertures as seen in FIGS. 1A, Band C to be formed in the continuous web of material 24. The computer281, having the memory, is electrically coupled with a programmablelogic controller 282. The programmable logic controller 282 is furtheroperably controllably coupled to the rotatable punch and die assemblies140 and 210, respectively as seen in FIGS. 3, 4 and 5, as well as themotor 23 and the coil advancing device 30. Still further, the controller282 is operably controllably coupled to the punch orientation assembly160, and punch movement assembly 190 as seen in FIGS. 5 and 6, as wellas to the fluid powered actuator 235 which positions the moveable dieblock 230 along the course of travel 240. As seen in FIG. 7, a highfluid pressure control unit of conventional design 283 is provided, andwhich is operable to provide a reservoir of high pressure fluid whichmay be supplied by means of a plurality of fluid delivery and returnconduits which are generally indicated by the dotted lines labeled 284to the plurality of fluid powered actuators which have been discussedabove, in the present application. Still further, each of the fluidpowered actuators are coupled to an electrically actuated valve andsensor arrangement which is generally indicated by the numeral 285. Thiselectrically actuated valve and sensor arrangement is coupled both influid flowing relation relative to the high fluid pressure control unit283 and electrically to the controller 282. Still further, fluidconduits 286 are provided for each of the fluid powered actuators,motors or the like, and which are operable for the delivery and returnof high pressure fluid which is sent to the respective fluid poweredactuators in order to render the web forming machine 10 operable. Aswill be appreciated by a study of FIG. 7, the programmable logiccontroller 281, in response to the memory included within the computer281, indexes or appropriately rotates the respective rotatable punch anddie assemblies 140 and 210 by means of the motors 104 and 134, such thatthey are in appropriate orientations one relative to the other, andfurther selectively positions the continuous web of material 24 in therespective work stations 72, 73 and 260. After this step of indexing,and with the respective assemblies 140 and 210 no longer rotating, thecontrol system 280 by means of the programmable logic controller 282 isoperable to move the punch assembly 140 into penetrating contact, forexample, with the top surface of the continuous web of material 24 andinto mating relation or cooperation relative to the underlying dieassembly 210. Other assemblies may be further controlled by theprogrammable logic controller in order to assist in the appropriatemovement of the continuous web of material 24 through the respectivework stations. The indexing of the respective assemblies 140 and 210 maybe repeated a number of times in order to form a plurality of apertures52 and 53 before the continuous web is advanced to the next downstreamwork station. This invention therefore provides a convenient means bywhich complex patterns of apertures may be formed in a work piece 40without the need of a multiplicity of presses. Therefore, the footprintof the present invention on a factory floor 11 is much smaller than theprior art assemblies utilized heretofore.

Operation

The operation of the described embodiment of present invention isbelieved to be readily apparent and is briefly summarized at this point.

A web forming machine of the present invention is shown in FIG. 1 andfollowing and includes a first rotatable assembly 140. A secondrotatable assembly 210 is positioned in spaced relation relative to thefirst rotatable assembly, and wherein a gap 214 is defined between thefirst rotatable assembly 140, and the second rotatable assembly 210. Aweb of material 24 to be formed is received in the gap 214. Stillfurther, the web forming machine 10 includes a means for reciprocallymoving the first rotatable assembly 125 into contact with the web 24,and into mating relation relative to the second rotatable assembly 210.In the embodiment of the invention as shown, this first rotatableassembly comprises a rotatable punch assembly 140, and the secondrotatable assembly comprises a rotatable die assembly 210. The webforming machine 10 further includes a first selectively actuatable motor134 which is disposed in force transmitting relation relative to therotatable punch assembly 140 and which causes the rotatable punchassembly to rotate to a predetermined orientation relative to therotatable die assembly 210. Further, a second selectively actuatablemotor 243 is disposed in force transmitting relation relative to therotatable die assembly 210 and which causes the rotatable die assembly210 to rotate to a predetermined orientation relative to the rotatablepunch assembly. Still further, a controller 282 is controllably coupledto the first and second selectively actuatable motors 134 and 243, andthe means for reciprocally moving the rotatable punch assembly 125 intopenetrating contact with the web, and into subsequent mating relationwith the rotatable die assembly 210. In the apparatus 10 as shown, thecontroller 282 first causes the rotatable punch and die assemblies toeach be positioned in appropriate predetermined orientations, and thensecondly, causes the rotatable punch assembly 140 to reciprocally moveinto penetrating contact relative to the continuous web 24. As discussedin the paragraphs above, the rotatable punch assembly 140 has aplurality of punches 153 which are positioned at various locations aboutthe exterior surface 150 thereof, and the rotatable die assembly 210 hasa plurality of dies 234 positioned at various locations about theexterior surface 223 thereof.

In operation, the individual punches 153 are operable to mate with theindividual dies 234. To effect this, the controller 282 selectivelyactuates the respective first and second motors 134 and 243 to rotatethe rotatable punch assembly 140 and rotatable die assembly 210 so as tosubstantially coaxially align mating punches 153 and dies 234. In thearrangement as shown, the movement of the first rotatable punch assemblyinto contact with the second rotatable die assembly 210 is along alinear path of travel 240 (FIG. 5) once the respective assemblies havestopped rotating. The movement of the first rotatable assembly 140relative to the second rotatable assembly 210 causes the penetration,severing or permanent deformation of the continuous web of material 24which is positioned in the gap 214. A punch movement assembly 190 isprovided and seen in FIG. 6, and which is operable to move punches 153along a substantially parallel path of travel 201 relative to theexterior facing surface 150 of the rotatable punch assembly 140. Stillfurther, the selectively rotatable die assembly 210 includes a moveabledie block 230 which is operable to move individual dies 234 along asubstantially parallel path of travel 240 relative to the exteriorfacing surface 223 thereof, such that it may be substantially alignedwith the moveable punches 153 positioned thereabove. In this manner, theapparatus 10 allows for design flexibility with respect to the formationof various apertures 52 and 53 at various locations in the continuousweb as seen in FIGS. 1A, 1B and 1C, respectively. A drive assembly 204and 235 (FIG. 6) is provided for each of the punch movement and diemovement assemblies in order to selectively position the respectivepunches 153 and dies 234 along individual courses of travel. Yetfurther, the present apparatus 10 further includes a punch orientationassembly 160 (FIG. 5) and which is operable, in a first mode ofoperation, to position at least one punch 153 in a first position,whereby it extends substantially radially, normally, outwardly relativeto the exterior facing surface thereof, and in a second mode ofoperation permits the at least one punch 153 to move from the first to asecond position, and wherein the punch(s) are received internally of therotatable punch assembly 140 such that an aperture 52 or 53 is notformed when the rotatable punch assembly 140 moves into contact with therotatable die assembly 210.

Another aspect of the web forming machine 10 of the present inventionincludes at least one work station 72 or 73, and a selectively rotatableand moveable punch assembly 140 positioned above, and in spaced relationrelative to, the work station 72. Still further, the web forming machine10 includes a selectively rotatable die assembly 210 positioned belowthe work station 73 and which is operable to matingly cooperate with thepunch assembly 140. Still further, a web of material 24 is selectivelypositioned in the work station 73. The selectively rotatable punchassembly 140 is moveable along a path of travel 240 and into penetratingcontact with the web 24 and into mating relation relative to therotatable die assembly 210. A computer memory 281 stores at least onepattern of apertures 52 and 53, and which are to be formed in the web24, and as seen in FIGS. 1A, 1B and 1C, respectively. Still further, acontroller 282 is controllably coupled with each of the rotatable punchand die assemblies 140 and 210, and further controllably positions theweb 24 in the work station 73. The controller selectively causes therotational movement of the rotatable punch and die assemblies, and theselective positioning of the web. Still further, the controller causesthe rotatable punch assembly 140 to move along the path of travel 240and into penetrating contact with the web to form the at least onepattern of apertures which are stored in the memory. As earlierdiscussed, the selectively rotatable punch and die assemblies 140 and210 do not rotate when the rotatable punch assembly moves along the pathof travel 240 and into penetrating contact with the web 24.

The present invention further includes a method of forming a web 24 intoa work product 40, and which includes a step of providing a web ofmaterial 24 having top and bottom surfaces; and further defining a workstation 73, and selectively positioning the web of material 24 in thework station. Still further, the method includes the step of providing aselectively moveable and rotatable punch assembly 140, and positioningthe moveable and rotatable punch assembly in spaced relation relative tothe top surface of the web. The method also further includes the step ofproviding a selectively rotatable die assembly 210 and positioning theselectively rotatable die assembly in an adjacent position relative tothe bottom surface of the web. The method includes the step of formingat least one aperture 52 or 53 in the web of material 24 by moving therotatable punch assembly into penetrating contact with the top surfaceof the web and into mating engagement with the underlying rotatable dieassembly. After the step of providing the rotatable die assembly 210,and before the step of moving the rotatable punch assembly intopenetrating contact with the web of material 24, the method includes thestep of indexing the respective rotatable punch and die assemblies 140and 210 relative to the top and bottom surfaces 50 and 51 of the webmaterial 24. The method of the present invention further includes thestep of providing a computer memory stored in a computer 281 and whichstores at least one pattern of apertures to be formed in the web 24, andproviding a controller 282 which is electrically coupled to the memoryand which is further operably coupled to the rotatable punch and dieassemblies 140 and 210, respectively. In the present method, thecontroller 282 indexes the respective rotatable punch and die assemblies140 and 210, and then further selectively positions the web of material24 in the work station 73. After the step of indexing, the controller isoperable to move the rotatable punch assembly 140 into penetratingcontact with the top surface of the web and into mating relationrelative to the rotatable die assembly 210.

Therefore it will be seen that the present invention provides aconvenient means of forming products 40 from a continuous web 24 in afashion not possible heretofore. Still further, the apparatus of thepresent invention 10 is compact and has a reduced factory footprint inrelative comparison to the prior art devices and other assembliesutilized to form products of this type. Still further, the presentapparatus provides a convenient means whereby patterns of apertures canbe stored in a computer memory and thereafter formed in a continuous webof material in a fashion not possible heretofore.

In compliance with the statute, the invention has been described inlanguage more or less specific as to structural and methodical features.It is to be understood, however, that the invention is not limited tothe specific features shown and described, since the means hereindisclosed comprise preferred forms of putting the invention into effect.The invention is, therefore, claimed in any of its forms ormodifications within the proper scope of the appended claimsappropriately interpreted in accordance with the doctrine ofequivalents.

1. A web forming machine, comprising: a first independently andselectively rotatable assembly having a substantially horizontallydisposed axis of rotation; a second independently and selectivelyrotatable assembly positioned in spaced relation relative to the firstrotatable assembly, and wherein a gap is defined between the firstrotatable assembly, and the second rotatable assembly, and wherein a webof material to be formed is received in the gap, and wherein the secondrotatable assembly has a substantially horizontally disposed axis ofrotation; and means for reciprocally moving the first rotatable assemblyinto contact with the web, and into mating relation relative to thesecond rotatable assembly, and wherein the first rotatable assemblymoves along a substantially linear and vertically oriented path oftravel.
 2. A web forming machine as claimed in claim 1, and wherein apunch is borne by the first rotatable assembly, and wherein thereciprocal movement of first rotatable assembly causes the punch topenetrate the web to form an aperture.
 3. A web forming machine asclaimed in claim 1, and wherein a severing tool is borne by the firstrotatable assembly, and wherein the reciprocal movement of the firstrotatable assembly causes the severing tool to cut the web of material.4. A web forming machine as claimed in claim 1, and wherein the web ofmaterial may be permanently deformed, and wherein a deforming tool isborne on the first rotatable assembly, and wherein the reciprocalmovement of the first rotatable assembly causes the deforming tool todeform the web of material.
 5. A web forming machine as claimed in claim1, and wherein a severing tool, deforming tool, and a punch are borne onthe first rotatable assembly, and wherein the first rotatable member maybe selectively indexed into given orientations relative to the secondrotatable member so as to permit each of the severing tool, deformingtool and punch to be reciprocally moved into contact with the web ofmaterial.
 6. A web forming machine as claimed in claim 1, and whereinthe first rotatable assembly comprises a rotatable punch assembly, andwherein the axis of rotation of punch assembly is substantially parallelto the web of material, and wherein the punch assembly has an exteriorfacing surface, and wherein a plurality of punches extend normallyoutwardly relative to the exterior facing surface.
 7. A web formingmachine as claimed in claim 1, and wherein the first rotatable assemblycomprises a rotatable punch assembly, and the second rotatable assemblycomprises a rotatable die assembly, and wherein the web forming machinefurther comprises: a first, selectively actuatable motor disposed inforce transmitting relation relative to the rotatable punch assembly andwhich causes the rotatable punch assembly to rotate about thesubstantially horizontal axis to a predetermined orientation relative tothe rotatable die assembly; a second, selectively actuatable motordisposed in force transmitting relation relative to the rotatable dieassembly and which causes the rotatable die assembly to rotate about thesubstantially horizontal axis to a predetermined orientation relative tothe rotatable punch assembly; and a controller controllably coupled tothe first and second selectively acutatable motors, and the means forreciprocally moving the rotatable punch into penetrating contact withthe web and into mating relation relative to the rotatable die assembly,and wherein the controller first causes the rotatable punch and dieassemblies to each be positioned in the respective predeterminedorientations, and then secondly causes the rotatable punch assembly toreciprocally move into penetrating contact with the web.
 8. A webforming machine as claimed in claim 7, and wherein the rotatable punchassembly and the rotatable die assembly each have an exterior facingsurface, and wherein the rotatable punch assembly has a plurality ofpunches positioned at various locations about the exterior surfacethereof, and the rotatable die assembly has a plurality of diespositioned at various locations about the exterior surface thereof, andwherein individual punches are operable to mate with individual dies,and wherein the controller selectively actuates the respective first andsecond motors to rotate the respective rotatable punch assembly androtatable die assembly so as to substantially coaxially align matingpunches and dies.
 9. A web forming machine as claimed in claim 1, andwherein the means for reciprocally moving the first rotatable assemblycomprises a hydraulic cylinder and moveable ram, and wherein themoveable ram is affixed in force transmitting relation relative to thefirst rotatable assembly, and is operable to reciprocally move the firstrotatable assembly along the substantially linear, and verticallyoriented path of travel into contact relative to the web, and intomating relation relative to the second rotatable assembly to penetrate,sever and/or permanently deform the web of material.
 10. A web formingmachine as claimed in claim 1, and wherein the first rotatable assemblycomprises a rotatable punch assembly which has an exterior facingsurface, and wherein at least one punch is moveably borne on therotatable punch assembly, and which is operable to travel along asubstantially radially inwardly path of travel from a first position,wherein the at least one punch extends outwardly relative to theexterior facing surface, to a second position, wherein the at least onepunch is received substantially internally of the rotatable punchassembly.
 11. A web forming machine as claimed in claim 10, and furthercomprising: a punch orientation assembly borne by the rotatable punchassembly and which is operable in a first mode of operation to positionthe at least one punch in the first position, and in a second mode ofoperation permits the at least one punch to move from the first to thesecond position, and wherein at least one punch moves along asubstantially horizontal path of travel.
 12. A web forming machine asclaimed in claim 11, and further comprising: a means for placing thepunch orientation assembly in the first and second modes of operation.13. A web forming machine as claimed in claim 10, and wherein the secondrotatable assembly comprises a rotatable die assembly, and wherein theweb forming machine further comprises: a punch movement assembly borneby the rotatable punch assembly, and which is operable to move at leastone punch along a course of travel which is substantially parallel tothe axis of rotation of the rotatable punch assembly to change therelative position of the punch with respect to the exterior facingsurface; a die movement assembly borne by the rotatable die assembly,and wherein the rotatable die assembly has an exterior facing surface,and wherein the die movement assembly is operable to selectively move atleast one die along a course of travel which is substantially parallelto the axis of rotation of the rotatable die assembly; and a driveassembly borne on each of the rotatable punch and die assemblies, andwhich is operably coupled to the respective punch and die movementassemblies, and which moves the respective at least one punch and die toa predetermined position relative to the exterior facing surfaces of therespective rotatable punch and die assemblies.
 14. A web forming machineas claimed in claim 1, and further comprising: a computer memory whichstores at least one pattern of apertures which are to be formed in theweb; and a controller electrically coupled with the computer memory, andfurther controllably coupled with each of the first and secondindependently and selectively rotatable assemblies, and furthercontrollably positioning the web in the work station, and wherein thecontroller selectively causes the rotational movement of the respectivefirst and second rotatable assemblies and the selective positioning ofthe web, and further causes the first rotatable assembly to move alongthe path of travel and into penetrating contact with the web, and inmating relation with the second rotatable assembly to form the at leastone pattern of apertures which are stored in the memory.
 15. A webforming machine comprising: a work station; a ram mounted above the workstation, and which has a distal end, and which is reciprocally moveablealong a substantially linear, and vertically oriented path of travelrelative to the work station; a punch assembly positioned above the workstation, and mounted on the distal end of the ram, and which is furtherselectively, and independently rotatable about a first axis of rotationrelative thereto, and wherein the distal end of the ram carries thepunch assembly along the reciprocal path of travel both into, and out ofthe work station; a die assembly positioned below the workstation, andwhich is selectively, and independently rotatable about a second axis ofrotation relative thereto, and wherein the first and second axes are insubstantially horizontal and parallel spaced relation, one relative tothe other; a web of material selectively positioned in the work station,and wherein the punch assembly is carried by the distal end of the raminto penetrating contact with the web of material and into matingengagement with the rotatable die assembly, and wherein the first andsecond axes of rotation are substantially parallel relative to the webof the material; and a controller which is controllably coupled witheach of the selectively rotatable punch and die assemblies, and thefluid powered ram, and wherein the controller selectively andindependently rotates the respective punch and die assemblies to givenpositions, selectively positions the web, and further causes the fluidpowered ram to carry the punch assembly into penetrating contact withthe web.
 16. A web forming machines, comprising: a work station; a webof material positioned in the work station; an independently andselectively rotatable and substantially vertically moveable punchassembly, having a plurality of moveable punches mounted above the webof material in the work station, and which rotates about an axis ofrotation which is substantially parallel relative to the web ofmaterial; a punch movement assembly borne by the punch assembly, andwhich is operable to change the relative position of at least one punchwith respect to the punch assembly, and wherein the punch movementassembly moves along a substantially horizontal path of travel; a punchorientation assembly borne by the punch assembly and which is operableto selectively act upon at least one punch so as to cause the at leastone punch to extend outwardly from, or be received within the punchassembly; an independently and selectively rotatable die assemblypositioned in the work station and below the web of material, and whichrotates about an axis of rotation which is substantially parallelrelative to the web of material; a die movement assembly borne by thedie assembly, and which selectively moves at least one die relative tothe die assembly, and wherein the die movement assembly moves along asubstantially horizontal path of travel; a computer memory which storesat least one pattern of apertures which are to be formed in the web; anda controller which is operably coupled to the computer memory; punchassembly; die assembly; punch and die movement assemblies; and the punchorientation assembly so as to cause the punch assembly to selectivelymove along a substantially vertical path of travel into contact with theweb, and into mating contact with the die assembly so as to form the atleast one pattern of apertures in the web.
 17. (canceled)